Hardfacing material

Abstract

A method of producing a hard metallic material by forming a mixture containing at least 55% iron and at least one of boron, carbon, silicon and phosphorus. The mixture is formed into an alloy and cooled to form a metallic material having a hardness of greater than about 9.2 GPa. The invention includes a method of forming a wire by combining a metal strip and a powder. The metal strip and the powder are rolled to form a wire containing at least 55% iron and from two to seven additional elements including at least one of C, Si and B. The invention also includes a method of forming a hardened surface on a substrate by processing a solid mass to form a powder, applying the powder to a surface to form a layer containing metallic glass, and converting the glass to a crystalline material having a nanocrystalline grain size.

1. An Fe-based alloy hardfacing material having a composition selected from the group consisting of (Fe 0.8 Cr 0.2 ) 79 B 17 W 2 C 2 , (Fe 0.8 Cr 0.2 ) 73 Mo 2 W 2 B 16 C 4 Si 1 Mn 2 , (Fe 0.8 Cr 0.2 ) 75 Mo 2 B 17 C 5 Si 1 , Fe 63 Cr 8 Mo 2 B 17 C 5 Si 1 Al 4 , (Fe 0.8 Cr 0.2 ) 75 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 73 Mo 2 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 72 Mo 2 W 7 B 17 C 5 Si 1 Gd 1 , (Fe 0.8 Cr 0.2 ) 71 Mo 2 W 2 B 17 C 5 Si 1 Gd 2 , and (Fe 0.8 Cr 0.2 ) 74 Mo 2 W 2 B 17 C 4 Si 1 , the Fe-based alloy hardfacing material having a microstructure comprising devitrified nanocrystalline Fe-based alloy grains having a grain size in the range of from about 75 nanometers to about 125 nanometers, the microstructure further comprising second phase precipitates, the Fe-based alloy hardfacing material having a hardness of at least about 9.2 GPa and a tensile elongation of from about 5% to about 180%. 
     
     
       2. The Fe-based alloy hardfacing material of  claim 1 , wherein the hardfacing material has a porosity of less than or equal to about 5%. 
     
     
       3. The Fe-based alloy hardfacing material of  claim 1 , wherein the hardfacing material has a porosity of less than or equal to about 1%. 
     
     
       4. An Fe-based alloy hardfacing material having a composition selected from the group consisting of (Fe 0.8 Cr 0.2 ) 75 Mo 2 B 17 C 5 Si 1 , Fe 63 Cr 8 Mo 2 B 17 C 5 Si 1 Al 4 , (Fe 0.8 Cr 0.2 ) 75 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 73 Mo 2 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 72 Mo 2 W 2 B 17 C 5 Si 1 Gd 1 , and (Fe 0.8 Cr 0.2 ) 71 Mo 2 W 2 B 17 C 5 Si 1 Gd 2 , the Fe-based alloy hardfacing material further having a microstructure comprising at least some amorphous glass structure, at least some crystalline structure comprising nanocrystalline grains of Fe-based alloy having a grain size in the range of from about 75 nanometers to about 125 nanometers, and second phase precipitates at grain boundaries, the Fe-based alloy hardfacing material having a hardness of at least about 9.2 GPa and a tensile elongation of from about 0.5% to about 60%. 
     
     
       5. An alloy hardfacing material having a composition selected from the group consisting of (Fe 0.8 Cr 0.2 ) 81 B 17 W 2 , (Fe 0.8 Mo 0.2 ) 83 B 17 , Fe 83 B 17 , (Fe 0.8 Cr 0.2 ) 79 B 17 W 2 C 2 , (Fe 0.8 Cr 0.2 ) 75 Mo 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 73 Mo 2 W 2 B 16 C 4 Si 1 Mn 2 , Fe 63 Cr 8 Mo 2 B 17 C 5 Si 1 Al 4 , (Fe 0.8 Cr 0.2 ) 75 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 73 Mo 2 W 2 B 17 C 5 Si 1 , (Fe 0.8 Cr 0.2 ) 72 Mo 2 W 2 B 17 C 5 Si 1 Gd 1 , (Fe 0.8 Cr 0.2 ) 71 Mo 2 W 2 B 17 C 5 Si 1 Gd 2 , and (Fe 0.8 Cr 0.2 ) 74 Mo 2 W 2 B 17 C 4 Si 1 , the hardfacing material having at least some structure comprising nanocrystalline grains of Fe-based alloy material having a grain size in the range of from about 75 nanometers to about 125 nanometers and second phase precipitates at grain boundaries, the alloy hardfacing material having a hardness of at least about 9.2 GPa and a tensile elongation of from about 5% to about 60%.